Durability Analysis of the Prototype Test Rig for Main Rotors

Karol Ścisłowski,Mirosław Wendeker,Ksenia Siadkowska,Krzysztof Skiba,Andrej Novák,Rafał Kliza,Tomasz Lusiak

doi:10.26552/com.c.2022.2.b148-b157

Karol Ścisłowski, Mirosław Wendeker + Show 5 more

Open Access

https://doi.org/10.26552/com.c.2022.2.b148-b157

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Abstract

This paper presents an analysis of the strength of a prototype test rig forÂ testing rotors of unmanned aerial vehicles. Digital design software was usedÂ for the design work that covered the creation of a virtual model of the testÂ rig and strength analysis of its key elements. The paper discusses the testÂ rig solutions, applied to date, of the small main rotor research. From theÂ assumed operational parameters and structural parameters of the rotor, theÂ main forces acting on the designed structure were determined: lifting force,Â reaction torque and empty mass of the test rig. Suitable actuators of theÂ control system enabling the regulation of the total pitch and periodic pitchÂ of the rotor, within the full range of the angle of attack, were selected for theÂ rotor under test. The FEM (Finite Element Method) strength analysis wasÂ carried out for the proposed support structure and the correctness of theÂ design was verified.

Highlights

The development of computer technology, artificial intelligence and miniaturisation in the broadest sense of the word, make the market for autonomous vehicles and unmanned remotely controlled vehicles grow rapidly
Before a new aircraft is introduced to the market, a number of simulation and bench tests are required
Numerical analyses require advanced computational models to illustrate the operation of selected subsystems [2,3], while the bench tests require the construction of test rigs enabling stationary testing of conceptual solutions before their application in flight [4,5]

Summary

Introduction

The development of computer technology, artificial intelligence and miniaturisation in the broadest sense of the word, make the market for autonomous vehicles and unmanned remotely controlled vehicles grow rapidly. The simulation study of rotorcraft performance using the CFD method provides approximate values of the lift force or torque applied to the rotor It does not take into account dynamic deformations of rotor blades resulting from aerodynamic forces, inertia forces or the impact of the rotor control system [7] and they can significantly affect the operation of the rotor in real conditions. A solution may be a coupled FEM analysis in which the fluid flow affects the mechanical deformation of the components that, in turn, changes the nature of the flow Such analyses are, very time-consuming, especially as many tests are required to simulate all the major operating states of the rotor. The stiffness of the structure should be selected so that its natural frequency does not coincide with any of the harmonic frequencies generated by the rotor or the control system [26,27]

Methodology

Test rig design

FEM strength analysis

Structure optimisation

Discussion

Conclusions